Note: Descriptions are shown in the official language in which they were submitted.
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IMP~OVED SYSTEM FOR MAKING ABSORBENT PAPER PRODUCTS
Backqround of the Invention
1. Field of the invention
o
This invention relates, broadly speaking, to the field of absorbent consumer paper
- products, such as towels, wipes and toilet tissue. More specifically, this invention
10 relates to an improved drying fabric for making absorbent paper products, to the
system and method of making such products, and to the product itself. This fabric
design also lends itself to forming and transfer fabric applications, which may be
used for making absorbent or flat grade papers.
15 2. Description of the Prior Art
In all paper machines, paper stock is fed onto a traveling endless belt that is
supported and driven by rolls associated with the machine and which serves as
the papermaking surface of the machine. In one common type of paper machine,
20 two types of belts are used: one or more "forming" fabrics that receive the wet
paper stock from the headbox or headboxes, and a "dryer" fabric that receives the
web from the forming fabric and moves the web through one or more drying
stations, which may be through dryers, can dryers, capillary dewatering dryers or
the like. Forming, transfer, or drying belts can be formed from a length of woven
2~ fabric with its ends joined together in a seam to provide an endless belt. Fabrics
can be woven endless depending on the running length of the fabric. Fabrics for
this purpose generally include a plurality of spaced longitudinal warp filaments that
are oriented in a machine direction ("MD") of the paper machine, and a plurality of
shute (also called "weft" or"woof") filaments, oriented in a cross direction ("CD")
30 that is orthogonal to the MD direction. The warp and shute filaments are woven
together in a predetermined weave pattern that results in a distinctive pattern of
"knuckles" or raised crossover locations on the fabric where a warp filament
crosses over a shute filament, or vice versa. Such knuckles, when on the side ofthe fabric that contacts the paper web, whether it be a forming fabric, transfer, or a
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drying fabric, impart a depression or compressed area onto the paper web. The
pattern of those depressions have a great deal to do with the texture of the
finished product, irrespective of whether additional processing steps such as
creping or calendering are performed on the web.
A great deal of study has gone into developing complex fabrics for paper
machines in order to provide product that is textured in a way that will be wellreceived by consumers. For example, U.S. Patents 3,905,863 and 3,974,025 to
Ayers disclose a paper sheet and process for making it in which the back side of a
10 semi-twill fabric is imprinted on the sheet. The sheet has a diamond-shaped
pattern imprinted on it and after creping, lofted areas align in the cross direction of
the sheet. Only three-shed (meaning that the crossover pattern of each warp
filament will repeat every three shute crossovers) fabrics are used, which have
both machine direction warp and cross direction shute knuckles in the top surface
15 plane on the sheet side of the fabric.
U.S. Patent 3,301,746 to Sanford discloses a process using imprinted fabrics that
may be of a square or diagonal weave, as well as twilled or semi-twilled fabrics.
The fabrics are coplanar. The product is characterized by altemateiy spaced,
20 unbroken ridges of uncompressed fibers and troughs of compressed fibers, which
extend in the cross machine direction. U.S. Patent 4,157,276 to Wandel et al.
discloses a wet end papermaking fabric of at least a fiveshed, and preferably a
broken twill, in an "Atlas" binding with the shute counts at least 80% of the warp
counts. The warp and shute knuckles are also coplanar in the top surface plane
25 on the sheet side. The atlas binding generally has the warp going under I shute
and over (n-1 ) shutes in an n shed repeat on the sheet side.
U.S. Patent 4,161,1~5 to Khan refers to a paper forming fabric and to the weaves- themselves, which are 5-shed or greater and are woven in a non-regular twill
30 pattern such that threads in both the MD and CD have interlacings in each weave
repeat so as to be to be "evensided" and such that no MD or CD knuckle exceeds
more than three crossovers in length. Generally the MD and CD knuckles on the
sheet side of the fabric are coplanar in the top surface plane, although this is not a
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requirement. The patent refers to the above designs as "Granite" patterns. The
fabric has relatively short MD knuckles, no more than 3 crossovers, even-sided
fabrics, and little overlap of MD knuckles.
Trokhan, U.S. Patent 4,191,609, refers to a soft imprinted paper sheet that is
~ characterized by a patterned array of relatively closeiy spaced uncompressed
pillow-like zones each circumscribed by a picket-like lineament comprising
alternatively spaced areas of compacted and noncompacted fibers. The pillow likezones are staggered to both the MD and CD directions. The picket-like lineamentsare produced by the MD and CD knuckles in the top-surface plane on the sheet
side of the imprinting fabric. Trokan 4,239,065 refers to related paper making
clothing.
Trokhan 4,528,239, 4,529,480 and 4,637,859 refer to a soft, absorbent paper web,the process for making the webs, and the foraminous fabric (or deflection member)
used as an imprinVdrying fabric in the process. The paper web is characterized by
a relatively dense monoplanar, patterned, continuous network of compressed
fibers and a plurality of relatively low density domes composed of uncompressed
fibers. Each low density dome is completely encompassed and isolated by the
network of compressed fibers; the domes are also staggered with respect to both
the MD and CD directions. The fabric - or foraminous deflection member - is
composed of a woven base on its wear side and a monoplanar, continuous
network surface formed by a photosensitive resin on its sheet side.
The fabrics discussed above and the products made therefrom have proven
relatively successful. However, the industry continues to strive for fabrics,
processes and products that are superior in such ways as manufacturing
efficiency, speed, and reliabiiity, and in terms of product bulk, strength, texture and
handfeel. This invention provides a significant advance in all of those areas.
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Summarv of the Invention
These and various other advantages and features of noveity which characterize
the invention are pointed out with particularity in the claims annexed hereto and
5 forming a part hereof. However, for a better understanding of the invention, its
advantages, and the objects obtained by its use, reference should be made to thedrawings which form a further part hereof, and to the accompanying descriptive
matter, in which there is illustrated and described a preferred embodiment of the
invention.
Brief Desçription of the Drawings
FIG. I is a photograph depicting the fabric side, also referred to as the air side, of
an uncreped absorbent web that is fabricated according to a preferred
1~ embodiment of the invention;
FIG. 2 is a photograph depicting the fabric side, also referred to as the air side, of
an creped absorbent web that is fabricated according to a preferred embodiment
of the invention;
FIG. 3 is a diagrammatlcal depiction of a knuckle pattern in the top plane of a
thirteen shed fabric that represents a preferred embodiment of the fabric aspect of
the invention;
2~ FIG. 4 is a diagrammatical depiction of the weave pattern in the fabric shown in
FIG. 3;
FIG. 5 is a diagrammaticai depiction of the warp contour in the embodiment of
rlGS. 3 and 4;
FIG. 6 is a diagrammatical depiction of shute contour in the embodiment of FIGS.3 and 4;
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FIG. 7 is a diagrammatical depiction of an alternative preferred weave pattern to
that shown in FIG. 4;
,, FIG. 8 is a diagrammatical depiction of the warp contour in the embodiment of
5 FIG. 7;
FIG. 9 is a diagrammatical depiction of the shute contour in the embodiment of
FIG. 7;
10 FIG. 10 is a diagrammatical depiction of an alternative preferred weave pattern to
that shown in FIGS. 4 and 7;
FIG. 11 is a diagrammatical depiction of the warp contour in the embodiment of
FIG. 1U;
FIG. 12 is a diagrammatical depiction of the shute contour in the embodiment of
EIG. 10;
FIG. 13 is a photograph that is a lite transmission photo of creped product
20 according to the invention;
FIG. 14 is yet another example of the bulky ridges produced from yet another
alternative preferred shed pattern, shown on the fabric or air side of an uncreped
towel;
FIG. 15 is photograph taken of the fabric shown in FIG 4 along the axis which
creates the bulk ridges;
FIG. 16 is a photo of the fabric side of an uncreped produced with the fabric
30 shown in FIG 7;
FIG 17 is a photograph showing the opposite side, dryer side, of the uncreped
web shown in FIG 1;
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FIG 18 Is a photograph showing the opposite side, dryer side, of the creped web
shown in FIG 2; and
FIG 19 is a schematic representation of a typical papermaking process that wouldemploy fabrics made according to this invention.
Detailed Description of the Dl~fer,~d Embodiment(s)
The preferred embodiment of the invention involves the use of a high shed,
10 complex woven fabric in the forming, transfer and\or drying positions of a
papermaking system to make a soft absorbent paper product such as tissue and
towel. The distinct product is of a better quality (higher bulk, TWA, softness, CDS)
than that made with conventionally woven through-dryer ("TD") fabrics. Use of the
high shed, complex woven fabric as a TD fabric also results in the expenditure of
15 less energy to dry the paper sheet and better release of the paper sheet from the
TD fabric. It also presents the possibility of increasing the sanded knuckle area on
the sheet side of the TD fabric to increase sheet tension after the creping step at
high speeds, without losing product bulk. The invention embraces the distinct
tissue product, the process for making it, and the complex woven fabric itself.
Referring now to FIG 1, which is a photograph depicting the TD fabric side or air
side of an uncreped absorbent paper sheet made according to the preferred
method of the invention, it will be seen that the high bulk absorbent paper product
is characterized on its air side by essentially continuous, low density ridges of
25 substantiaily uncompressed fibers running parallel to one another and at an angle
to both the machine direction ("MD") and cross direction ("CD") of the product.
The ridges are bounded or defined by an angular pattern of long, overlapping,
discrete, MD oriented, oblong areas of highly compressed, dense fibers. As will
be described more fully below, the dense areas correspond to the MD (or long
30 warp) knuckles in the sheet side of the TD fabric, while the low density ridges
correspond to the continuous channels woven into the fabric. For a typical TD
fabric with mesh count of 44 x 38 and yarn diameters of 0.35 mm and 0.40 mm,
the ridges are about 0.054" wide and about 0.068" from each other, centerline to
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centerline. Ridge widths for other expected mesh and diameters for TD and
forming fabrics are shown in the table below:
Mesh Count Yarn Diam RidgeWidth CLto CL
24 x 2~ 0.40mm 0.1489" 0.1667"
180 x 180 0.12mm 0.0147" 0.0160"
Each ridge extends along or parallel to a first axis that is disposed at a first angle
with respect to the cross-direction of the paper product. Preferably, the flrst angle
is substantially within the range of greater than 68 degrees but less than 90
10 degrees, with a more preferred range of 70-90 degrees. The product is also
characterized by second parallel axes formed by each of the oblong areas with
other, overlapping oblong areas not adjacent to a same side of a same bulky
ridge. The second axes form a second angle with respect to the cross-direction of
the paper product, which is preferably less than about 28 degrees and more
15 preferably less than about 25 degrees. The oblong areas along the second axisoverlap by at least 60 percent, and by at least 0.035 inches. The oblong areas
reside in a plane that is depressed with respect to the ridges by at least 0.005inches.
20 Referring now to FIG 2, which is a photograph depicting the TD fabric side of a
creped absorbent paper sheet made according to the preferred method of the
invention, it will be seen that the high bulk absorbent paper product is
characterized on its air side by essentially continuous, low density ridges of
substantially uncompressed fibers running parallel to one another and at an angle
25 to both the machine direction ("MD") and cross direction ("CD") of the product.
The creping process tends to foreshorten the sheet by the amounts of speed
differential between the Yankee dryer and the reel. The crepe "C" is defined by:C = (Y-R)/R
(where C = crepe, Y = Yankee speed, and R = Reel speed)
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Creping the sheet will change the preferred angles I and 2 on the uncreped sheet.
The amount change depends on the crepe level. The foreshortened angle can be
calculated as follows:
Angle 1c = tan-1 { (1/(1~C) ) x tan Angle 1u}
Angle 2c = tan~' { (1/(~+C)) x tan Angle 2u}
(where Angle 1c = Angle 1 of the creped sheet, Angle 2c = Angle 2 of
the creped sheet, Angle 1u = Angle 1 of the uncreped sheet, and
Angle 2u = Angle 2 of the uncreped sheet)
10 Thus, at 12% crepe, the preferred range for Angle 1c on the creped sheet is 68~ to
90~ and Angle 2c must be less than 25~. As may also be seen in the photograph
that is provided in FIG. 2, the bulky ridges have periodic indentations therein that
do not substantially compress the fibers of said web, whereby the product is
prevented from having an undesirable twill-like appearance.
FIG. 3 is a diagrammatical depiction of the fabric weave pattern in which only the
long warp knuckles of a fabric according to the invention reside in a top plane of
the fabric that will correspond to the deepest penetration of the fabric into the
absorbent paper product during formation or drying. These knuckles then produce
20 the oblong compressed areas in the paper. The long or raised MD oriented warpknuckles have been sanded to provide a flat surface in the top plane of the fabric.
FIG. 4 depicts the fabric itself, according to the preferred embodiment of the
invention.
25 As may be seen in FIGS. 3 and 4, the fabric includes a plurality of shute threads
that extend substantially parallel to each other in a cross-direction of the drying
fabric, and a plurality of warp threads extending substantially parallel to each other
in a machine direction of the drying fabric. The shute and warp threads are woven
together so as to define a number of relatively long warp knuckles at locations
30 where one of the warp tl~reads crosses over at least four of the shute threads. In
correspondence with the pattem and angles on the absorbent paper product that
are discussed above, the long warp knuckles are disposed in a pattern so as to
form a group of first parallel axes of bulky ridges that are defined by long warp
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knuckles which are positioned next to each other on adjacent warp threads. The
first axes are disposed at a first angle with respect to the cross-direction of the
drying fabric, which is substantially within the range of greater than 68 degrees but
. iess than 90 degrees. The long warp knuckles of the fabric also form second
5 parallel axes that are defined by each of the long warp knuckles with other,
~ overlapping long warp knuckles on nearby, but not immediately adjacent, warp
threads. The second axes form a second angle with respect to the cross-directionof the drying fabric, which is less than about 28 degrees. The complex fabric has
only long, MD knuckles in the top surface plane on the sheet side of the fabric: no
CD knuckles are present. Typically, there is a 0.008" - 0.010" difference in depth
between the top plane MD knuckles and the closest CD knuckle crossover before
surfacing. (It is noted that Khan, U.S. Patent 4,161,195, defines "coplanar" as
being within 0.0005"). The length of these long warp knuckles ("LWK") will depend
on the exact weave, mesh count, yarn size, and the amount of sanding but will
always be longer than 0.060" for a TD fabric. The overlap of the LWK should be
maximized to obtain the greatest benefit from the invention. Overlap is a function
of the knuckle length and angles and can be expressed as a percentage of
knuckle length (i.e., 100% represents overlap equal to the length of the knuckle or
two parallel knuckles of equal length, and 0% represents no overlap or two
knuckles out of phase with one another). The second angle defined above most
det~r"lines the amount of overlap. In the preferred embodiment of the invention
for TD fabrics, each long warp knuckle overlaps adjacent long warp knuckles
along the second axis by at least 60 percent and by at least 0.035 inches. The
second angle must be kept as low as possible to maximize overlap. In Figure 3,
LWK length is 0.100", overlap is approximately 70%, the first angle is about 72.8~
and the second angle is about 23.3~. Preferably, all four measurements are within
the specified ranges to produce the paper property benefits of the invention. All
four measurements are a function of weave sequence, yarn diameter, and mesh
count.
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A few examples of fabrics that meet these criteria are listed below:
Mesh Yarn Knuckle Knuckle Angle 1Angle 2
Fabric # Count Size Length Overlap
51 44 x 38 0.35 mm x 0.40 mm 0.120" 75% 73.9~ 16.1~
2 44x34 0.35 mm x0.45 mm 0.090~ 69% 72.8~ 23.3~
3 44 x 38 0.35 mm x 0.40 mm 0.100" 70% 70.9~ 21.1~
4 44 x38 0.35 mm x0.40 mm 0.090" 67% 77.8~ 24.9~
10 The inventors have found that such a fabric will impart improved sensory,
aesthetic and crepeability characteristics to an absorbent paper web that is dried
thereon.
The inventors have also determined that the best product characteristics will be15 achieved when the warp and shute threads are woven in a shed count that Is atleast nine. To achieve the desired paper characteristics, in at least one section of
the repeat pattern the LWK should span at least 4 CD crossovers. Preferred
embodiments have the LWK span at least 4 CD crossovers in two sections within
the MD repeat. The pattern repeat must also be such that the MD warp yarn has
20 at least 4 interlacings with CD yarns in a pattern repeat; even more interlacings (5
or 6~ are preferred to get better fabric stability.
Both fabric stability and the difference in height between the top surface warp
knuckles and below top sur~ace plane shute knuckles on the sheet side are
25 facilitated by weave designs which generate lateral crimp in the CD shute yarns.
Lateral crimp is defined as a condition where the yarns travel side to side as well
as up and down within the fabric weave. Within the series of fabric designs
discussed, lateral crimp occurs when two adiacent yams (2 warps or 2 shutes)
traveling in opposite directions (ie one traveling down and the other traveling up)
30 come between two adjacent yarns (2 shute or 2 warp) traveling 90~ from the
direction of the first two yams. Lateral crimp can also be augmented by having the
warp yarn pass over or under multiple shute yarns. These resulting designs are
not "even sided," as is that disclosed in U.S. Patent 4,161,195 to Khan, i.e. the
number of crossovers by the warp yarns over the shute yams on one side of the
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fabric is not the same, or within 1, of the number of crossovers on the other side of
the fabric. As is seen in the examples below, fabrics according to this invention
are decidedly not even-sided.
.
5 Lateral crimp may be facilitated through varying the fabric break among other
- parameters. The break refers to the number of CD yarns which are skipped on
any two adjacent MD yarn before the next pattern repeat begins. Break is a
function of the shed of the fabric. A 5-shed weave has 4 possible fabric breaks, 1,
2, 3, & 4. Breaks 1 and 4 are identical but are mirrored images of one another.
10 Breaks 2 and 3 are identical but are mirrored images of one another. Therefore,
with a 5-shed weave, there are only 2 unique breaks. The higher the shed, the
more unique break options. A "n" shed fabric, where "n" equals a prime number,
will yield n-1 possible break options, with (n-1)/2 being unique. When lateral crimp
occurs in one of the yarns the fabric structure changes such that either warps or
15 shutes will be out-of-plane with one another. The amount of planar differencebetween warp and shute has also been shown to be a function of mesh count,
yarn diameter, and techniques of manufacture such as the heat setting process.
The current invention uses the higher shed fabrics to generate break patterns that
bring only LWK in the top plane of the fabric, thus, creating the channels in which
20 low densification in the paper occurs. Fabrics of the invention are woven with
"breaks" of 3 or preferably 4 or higher.
In the preferred embodiment shown in FIG. 4, the warp and shute threads are
woven in a shed count of thirteen, and more specifically, as is illustrated
25 diagrammaticaliy in FIG. 5, in a warp pattern of five over, two under, four over and
two under. With this pattern, not only are the warp and shute knuckles out of
plane, but also, the two long warps are out of plane and require sanding to bring
both in the top plan surface. The break for this fabric is 4. This break in pattern
also helps sheet appearance and minimizes marking, since the resulting weave
30 then simulates a "broken twill" pattern. (A regular twill pattern is one which has a
succession of adjacent yarns that present on a fabric face equal length knucklescomprised of two or more crossovers in which each successive yarn advances its
weave repeat by one crossover from the preceding yarn, to form the characteristic
11
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diagonal iine.) The complex woven fabrics of this invention have a combination of
desired characteristics: only LWKs in the top surface plane on the sheet side
(Angle 1 > 68~); LWK be at least 0.06Q" long; optimum overlap (Greater than 60%)of the MD knuckles to produce continuous channels (Angle 2 < 28~); at least one
5 LWK spanning 4 or more crossovers in a pattern repeat; at least 3 MD interlacings
of the MD warp with the CD yarns in a pattern repeat; lateral crimp in CD yarns; no
"even-sidedness"; breaks of at least 3. When woven in this manner, the fabrics
have numerous sub-top-surface plane crossovers of warps and shutes which form
the bottom of the continuous channels and thus support the top of the ridges on
10 the tissue sheet. These sub surface cross-overs also give the ridges the
indentations discussed earlier, since they are of varying depths below the top
surface plane.
The complex fabrics can be woven and heat set for good stability and elongation
characterlstics. Yarn sizes can be in the range of 0.22 to 0.50 mm including thesame as those currently used on existing 4 or 5 shed fabrics (eg 0.35 mm warp,
0.40 mm shute); thus wear characteristics and fabric life can be very good. Yarnmaterial types can be polyester, polyamide, polypropopylene, PTFE, ryton, PEEK,
etc. Yams can have a round, oval, or flat (rectangular) shape.
Thirteen shed fabrics (i.e. the MD pattern repeats every 13 CD yarns) lend
themselves to weaves of this invention and are the preferred shed count; they are
particularly good for seaming. Shed counts of at least g are required to obtain the
desired fabric characteristics noted above.
2~
Again, the fabric of FIG. 5 has a warp pattern of 5 X 2 X 4 x 2 (5 over, 2 under, 4
over, 2 under); the break is 4. Warp yarns of 0.35 mm diameter and 0.45 mm
shute diameter were used. The top-surface plane on the sheet side has warp
knuckles at least 0.090" Iong; there are no shute knuckles. Knuckle overlap is
6g% while the first angle is 72.8~ and the second angle 2 is 23.3~. The design has
a break of 4. In each MD pattern repeat, the warp yarn spans first 5 CD yarn
crossovers and then 4 CD yarn crossovers; it thus interlaces with 4 CD yarns, asmay be seen in FIG. 5. The resulting design is not evensided, i.e. the MD yarn
12
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crosses 9 CD yarns on the sheet side and only 4 CD yarns on the other (roll) side
of the fabric. As is shown diagrammatically in FIG. 6, the CD yarn repeats in a
patternthatis4x1 x2x1 xlx1 x2x1 (4under, 1 over,2under, 1 over, 1
under, 1 over, 2 under, and 1 over). This weave pattern produces significant
5 lateral crimp in the CD yarns, which helps to keep the shute yarns below the top
- surface plane on the sheet side. The difference in height between the top surface
plane unsanded MD knuckies and the next closest CD crossover knuckle is about
0.~04" below the top surface plane for the example shown.
10 Another example of a 13 shed is seen in FIG. 7. For this weave the warp repeat is
6 x 2 x 3 x 2 (over 6, under 2, over 3, under 2). The fabric break is 3 and the yarn
size is 0.35 mm warp and 0.40 mm shute. The warp/shute count is 44/38. The
LWK length is 0.120", overlap is 75% (0.090"), the first angle is 73.9~ and the
second angle is 16.1~. The channels obtained with this fabric are very large and15 tend to be supported by an intermediate relatively short warp knuckle giving the
ridges on the paper a "chain-link" fence, dimpled, or "bagel" like appearance. The
warp and shute repeat patterns for this embodiment are shown in FIGS. 8 and 9.
Either of these warp patterns, as well as others that will be apparent to those
having ordinary skill in this area of technology, will be effective, as long as, within
20 one MD repeat, one of the warp threads crosses over at least four of the shute
threads to form a long warp knuckle of the type shown in FIG. 3. Preferably, thewarp and shute threads are woven so as to create lateral crimp in the shute
threads.
25 Higher sheds than 13 are acceptable and may be found to be advantageous.
In some forming and drying applications, the weaves discussed above may be
rotated 90~ so that the Long Warp Knuckle becomes a Long Shute Knuckle; there
are then no warp knuckles in the top plane of the fabric. These type of rotated
30 fabric weaves may be desirable in some forming applications or particular drying
applications, e.g. where the tissue paper is dried without creping.
13
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In drying and transfer applications mesh counts will typically be from 10 x 10 to
about 60 x 60. Forming applications would tend to have finer meshes, probably
up to about 120 x 120 counts.
5 Previously known weaves can not produce the results and advantages that inhereto the invention. "Satin" and "Atlas" weaves (1 under x (n-1 )) over on sheet side
with the opposite on the other side, as disclosed in the Wandel patent can produce
long MD knuckles but tend to have warp and shute knuckles in the top-surface
plane on the sheet side (i.e. "coplanar" and don't give laterai crimp; thus, they do
10 not have the parallel continuous channels required by the invention. They also do
not meet the angle specifications and number of interlacings required by the
invention to achieve its objectives. The "Granite" patterns of Khan are even sided,
have relatively short MD knuckles (no more than 3 MD crossovers), and fall
outside the criteria of this invention noted above. They may also have coplanar
1~ warp and shute knuckles on the top-surface plane on the sheet side.
As may be seen in FIG. 10, which is a lighttransmission photo of creped tissue
made according to the invention, the light oval shaped objects are areas of
compressed fibers that tend to be relatively dense and are generated by the MD
20 knuckles of the TD fabric. The dark areas are the ridges of relatively
uncompressed fiber which were nestled in the channels of the complex woven
drying fabric during the drying and pressing steps. In this example, the
uncompressed ridges run at an angle of about 70.9~ to the CD, which is the firstangle as defined above, and are about 0.054" wide, and about 0.068" from each
25 other, centerline to centerline. The second angle, as defined above, is about 21.1~
from the CD. Angle 1 of the uncreped sheet was 72.8~, and Angle 2 was 23.3~.
The continuous ridges of uncompressed fiber characteristic of this soft, absorbent
tissue are not of uniform height. They have occasional indentations caused by the
30 sub-surface crossovers of warp and shute strands on the sheet side of the
complex woven fabric. As may be seen in FIG. 2, these indentations help to
st~hiii~e the ridge areas and, more importantly, improve the aesthetics of the sheet
by giving the surface a more topographical, 3-dimensional appearance. By
1~
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breaking up the appearance of parallel continuous rows, the undesirable "twill"
pattern look associated with many fabric pattern markings is avoided. The
indentations do not substantialiy compress the fibers; thus the indented areas are
- still of a relatively low density, as can be seen in the FIG. 2. Depending on the
5 specific weave, mesh count, and yarn diameter of the fabrics of this invention, the
- sheet appearance may range from distinct, parallel ridges (a twill look) to almost a
random pebble pattern (a terri-cloth look). FIG. 11 shows yet another product
variant demonstratlng the concept of parallel ridges. In this example, the photodepicts the TD fabric side of uncreped towel web made using yet another TD
10 fabric weave that meets the criteria of this invention. Clearly visible are such
parallel ridges. For this weave, the warp repeat is 7x1 x1 x1 x2x1 (over 7, under 1,
over 1, under 1, over 2, under 1). The fabric break is 4 and the yarn size is
0.35mm warp and 0.40mm shute. The warp/shute count is 44x38.
15 FIG. 12 is a highly magnified photo of the fabric of FIG. 4 taken on a bias,
specifcally along the first axis as defined above. It clearly shows fabric channels
which are below the top surface plane which have subsurface CD crossovers to
help support the sheet. In some of the designs where the ridges are particularlywide or high, an occasional MD knuckle may also be incorporated to help stabilize
20 the high bulk, continuous ridges. This gives the ridges the appearance of having
craters, or of a chain link fence, or of connected bagels, as is shown in the
photograph that is provided as FIG. 13. It should be noted that on the opposite, or
"dryer side," of the soft absorbent sheet, the ridge areas appear as depressed
channels of uncompressed fibers bounded by the same array of compressed
25 fibers formed by the MD knuckles. (The "dryer side" is defined as the side of the
sheet not facing or against the drying fabric, i.e. the side against a Yankee or can
dryers; the side incident to the hot air in a TD or impingement dryer; and/or the
side against a capillary surface in a capillary type dewatering system.) The "dryer
side" of the sheet appears as the inverse of the "air side." FIGS 14 and 15 show30 the dryer side of the uncreped and creped sheet corresponding to FIGS 1 and 2.
Again the array of compressed fiber formed by the MD knuckles and associated
depressed channels are clearly visible.
SUBSTITUTE SHEET (RUL~ 26)
CA 022398l0 l998-06-l9
W 097/24487 PCT~US96t20367
The process for making the soft absorbent tissue described above was a through
drying process of the type that is well known in this area of technology, as
evidenced by U.S. Patent Sanford 3,301,746 the disclosure of which is
incorporated by reference as if set forth fully herein. Additional process
5 schematics can be seen in FIG 16. The process settings for this experiment areshown in Table 1. The stratified sheet was formed by a standard Valmet TWF
consisting of an Outer Forming Fabric ~OFF) and Inner Forming Fabric (IFF) of
representative designs. The forming end of the PM is not believed to be critical to
the invention; an SBR former or Fourdrinier could be used. The sheet was
10 transferred at about 18 - 22% dry to a TD fabric having a complex woven design of
the type described in this patent invention record. Some additional dewatering
was done on the TD fabric before through-drying to about 85% dry. The sheet
was drawn into the complex woven TD fabric by the action of the transfer and
dewatering vacuums; in this way the continuous ridges of relatively uncompressed15 fiber were formed. The transfer of the sheet may occur with or without any relative
speed difference between the IFF and TD fabrics. The side of the sheet againsVinthe TD fabric is referred to as the "air side," while that facing away from the TD
fabric as the "dryer side". The sheet was then patterned pressed onto the Yankeewhere the drying was completed before subsequent creping, calendering, and
20 reeling up.
The dryness values noted above are typical in the industry. The IFF/TD fabric
transfer could take place at 10% - 35% dry while the transfer to the Yankee dryer
could take place at 35~ - 95~ dry.
The TD papermaking process described above is only one way in which the soft,
absorbent tissue sheet could be made. The sheet drying could be completed by
the TD's alone with no Yankee or creping step. The TD's could be replaced by allcan dryers to remove the water and complete the drying. In fact, the forming,
30 transfer systems, and complex woven fabrics noted previously could be used with
numerous combinations of TD's, Yankees, can dryers, and/or capillary dewatering
units to complete the dewatering and drying of the sheet without overall
compaction to produce the desired bulky, soft, absorbent tissue product.
16
SuBsT~luTF SHEET (RULE 26)
CA 02239810 1998-06-19
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To achieve the distinctive, soft creped tissue product of this invention, the complex
woven drying fabric must be designed, woven, and heat set such that the fabric
has only long warp knuckles in the top plane of the sheet side, and that these
5 knuckles be in an array which bound, or define, subsurface channels running
parallel to each other and at an angle to both the MD and CD. The top plane of
the Sheet Side (SS) OT the fabric wou;d therellore look like FIG. 2, with the warp
knuckles corresponding to the compressed areas in the sheet and the channels
being the mechanism to create the paper ridges.
Tissue product of this invention has higher bulk, superior handfeel ("HF") and more
cross-direction stretch ("CDS") than fabrics described by the prior art. The "granite
weave" of Khan is a woven fabric manufactured by Albany International, which is
considered to be an excellent fabric and is state of the art. The information
1~ provided in Tables 1 and 2 compare product made from four fabrics according to
this invention with a 44 x 36 granite weave fabric and a finer 59 x 44 granite
weave fabric having the same type of weave as the 44GST fabric. All fabrics weresanded to about the same level (20% - 22%). All product was made on the same
TD paper machine, FIG 16, which is typical of those in common use throughout
20 the industry. Furnish and papermaking conditions are given in Table 1. Paper
property data is given in Table 2. Selected data represents actual points taken
about the same level of strength as seen in the MD and CD tensile comparisons.
SUBSI ITUTE SHEET (~IJLE 26~
CA 02239810 1998-06-19
W097/24487 PCTrUS96/20367
Tabie #1
PROCESS SETTINGS
Triai Fabric
Prior 1 2 3 4
Art
Overall 40% NSWK 40% NSWK 40% NSWK 40% NSWK 40% NSWK
Furnish 30% SHWK 30% SHWK 30% SHWK 30% SHWK 30% SHWK
(all trials) 30% Eu- 30% Eu- 30% Eu- 30% Eu- 30% Eu-
1 0 calyptus calyptus calyptus calyptus calyptus
Reel Speed 1,000 1,000 1,000 1,000 1,000
(mpm~
Crepe 98.2 99.8 99.1 99.3 97.4
Dryness (%)
TD Hood 475 468 477 465 481
Suppy Temp (~F)
TD Gas Flow 9.967 9.503 9.812 8.986 9.168
(SCFH)
TD Cleaning 330 168 202 123 420
Water (ppm)
Table ~ 2
PAPER PROPERTIES
Trial Fabric
Prior 1 2 3 4
Art
Basis Wgt (gsm) 24.5 24.9 25.5 25.125.2
Uncal Bulk 3.34 3.66 3.84 3.604.75
(1.0KPA, mm/10Plys)
Bulk/BW ('C,/gr) 13.6 14.7 15.1 14.318.7
MDT (gr/in) 3.18 399 363 352 322
CDT (gr/in) 189 218 193 216 175
MD Stretch (%) 17.0 20.4 18.6 18.819.0
CD Stretch (%) 6.6 8.5 8.7 7.6 11.2
Apparent 0.0734 0.0680 0.0662 0.0699 0.0536
Density (1/B/BW)
(9r/CC)
Handfeel ~ 1.00 1.05 1.20 1.151.05
~CII 11 lali t:d to prior art (~ 1.0)
18
SUBS~TUTE SHEET (RULE 26)
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W O97/24487 PCT~US96/20367
The uncreped bulk was 15 to 25% higher than that of the control product. The
creped sheet uncalendered bulk increased from 8 to 42% versus the control.
- Average softness ratings were up 5 to 20% versus the control.
Calendered MD stretch was up from 9 to 20% and CD stretch was up 15 to 70%
versus the control. The calendered CD stretch for one of the fabrics made from
this invention was 11.2% (absolute value) which is uniquely high for this TD
papermaking process. The increases in bulk, TWA, HF, and stretch are all
10 desirable characteristics for sanitary products - tissue, towel, napkins, etc.
All fabrics ran well in terms of sheet release at the pressure roll. The amount of
fiber washed out of the fabric at the cleaning section (TD PPM'S) was very low on
three out of the four fabrics, and well below the control. The amount of fiber
15 washed out of the fabric is inversely proportional to ease of release (high values
represent more fiber carry back and, therefore, poorer release). This also
suggests that the fabrics ran cleaner that the control which should improve fabric
life. The experimental fabrics dried better than the control. In most cases the
average TD supply temperatures were at or below the control, with while the
20 average sheet dryness post TD was about the same. Average gas flow was less
for all fabrics of this invention. An additional benefit from fabrics of this invention is
that the LWK's with greater overlap improves efficiency of the creping process.
Additionally, the higher uncalendered bulks suggest that the experimental fabrics
could be sanded more or the mesh count increased to take advantage of this gain.25 Since there is a large out-of-plane difference between the top surface plane warp
knuckles and the sub surface shute knuckles on these fabrics, increased sanding
could be done while maintaining all specs of invention and still getting good prod
quality. This would help adhesion and creping at high PM speeds on light weight
tissue. For example, at 30% sanded area, sheet tension increase by 20% at
30 constant paper strength over a control run using a prior art granite weave TD fabric having the identical sanded area.
19
SUBSTITUTE SHECT (RULE 2~)
CA 02239810 1998-06-19
W097/24487 PCT~US96/20367
In its application as a forming fabric the complex woven designs of this invention
may be used in all types of papermaking processes (sanitary tissue, flat paper
grades, liner board, etc.). The particular weave, mesh count, shed, and yarn size
may vary by application, but will all fall under the limitations imposed by the
5 invention.
It is to be understood, however, that even though numerous characteristics and
advantages of the present invention have been set forth in the foregoing
description, together with details of the structure and function of the invention, the
1~ disclosure is illustrative only, and changes may be made in detail, especially in
matters of shape, size and arrangement of parts within the principles of the
invention to the full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed.
SUBSTITIJTE SHEEr (RULE 26)
.
